Search Results (9)

The spiral case plays a role in providing stable and uniform water flow in the pump-turbine unit, and the overall structure with the surrounding concrete is an important foundation for the safe and stable operation of the unit and power plant. In order to clarify the comprehensive bearing capacity of preloading steel spiral case under pump operating conditions, this study is based on the theory of the fluid–structure coupling and contact model and uses ANSYS CFX 2021 R1 and mechanical to analyze the flow fluctuation characteristics and dynamic structural response of a preloading steel spiral case and surrounding concrete under different preloading pressures in the intermediate head pump condition. The results indicate that the main frequency of pressure fluctuations inside the main frequency ($1 f_n$) of pressure fluctuations inside the spiral case is influenced by the unstable flow. The contact state between the preloading steel spiral case and concrete is closely related to the relative magnitude of preloading pressure and hydraulic pressure. Higher preloading pressure can lead to an increase in initial preloading clearance, resulting in a decrease in contact area. The vortex motion inside the spiral case is the main factor affecting the distribution of deformation. The rotor–stator interaction also has a certain impact on the vibration of the spiral case structure, even though the influence of rotor–stator interaction on pressure fluctuation inside the spiral case is already small. The monitoring points where the maximum values of static stress and dynamic stress are located are different. Increasing the preloading pressure value does not always guarantee the safety of concrete structures, as the sticking contact area in early contact transfers most of the stress of the spiral case, resulting in significant stress concentration. Under the working conditions of this study, the concrete in contact with the inner edge and nose vane is subjected to excessive loads. Therefore, it is necessary to reinforce the structure with steel bars or other methods to improve its tensile strength. A minimum preloading pressure value of 3.2 MPa is beneficial for reducing the risk of concrete cracking. The research results can provide a deeper understanding of the behavior of preloading steel spiral cases under pump conditions and guide optimization design. Full article

During the transient process of load rejection, the hydraulic pressure applied to the pump-turbine and plant concrete changes dramatically and induces high dynamic stress on the spiral case. The preloading spiral case has been widely used in large-scale pumped-storage power stations due to its excellent load-bearing capacity. However, studies on the impact of preloading pressure on the structural response during load rejection are still few in number. In this paper, 3D flow domain and structural models of a prototype pump-turbine are designed to analyze the hydraulic characteristics and flow-induced dynamic behavior of the preloading steel spiral case under different preloading pressures during load rejection. The results show that the asymmetric design of the logarithmic spiral lines ensures an axially symmetric potential flow within the spiral case domain with uniform pressure distribution. Higher preloading pressure provides larger preloading clearance, leading to greater flow-induced deformation and stress, with their maximum values located at the mandoor and the inner edge, respectively. The combined effect of the asymmetrical shape, internal hydraulic pressure and unbalanced hydraulic force leads to an asymmetrical preloading clearance distribution, resulting in an asymmetrical distribution along the axial direction but a symmetrical characteristic near the waistline of the structural response. Stress variations at sections and between sections share similar characteristics during load rejection. It follows the same trend as the hydraulic pressure under lower preloading pressures, while there is a delayed peak of stress due to the delayed contact phenomenon when the preloading pressure reaches the maximum static head. The conclusions provide scientific guidance for optimizing the preloading pressure selection and structural design for the stable operation of units. Full article

A pump-turbine may generate high-amplitude hydraulic excitations during operation, wherein the flow-induced response of the spiral case and concrete is a key factor affecting the stable and safe operation of the unit. The preloading spiral case can enhance the combined bearing capacity of the entire structure, yet there is still limited research on the impact of the preloading pressure on the hydrodynamic response. In this study, the pressure fluctuation characteristics and dynamic behaviors of preloading a steel spiral case and concrete under different preloading pressures at rated operating conditions are analyzed based on fluid–structure interaction theory and contact model. The results show that the dominant frequency of pressure fluctuations in the spiral case is 15 $f_n$, which is influenced by the rotor–stator interaction with a runner rotation of short and long blades. Under preloading pressures of 0.5, 0.7, and 1 times the maximum static head, higher preloading pressures reduce the contact regions, leading to uneven deformation and stress distributions with a near-positive linear correlation. The maximum deformation of the PSSC can reach 2.6 mm, and the stress is within the allowable range. The preloading pressure has little effect on the dominant frequency of the dynamic behaviors in the spiral case (15 $f_n$), but both the maximum and amplitudes of deformation and stress increase with higher preloading pressure. The high-amplitude regions of deformation and stress along the axial direction are located near the nose vane, with maximum values of 0.003 mm and 0.082 MPa, respectively. The contact of concrete is at risk of stress concentrations and cracking under high preloading pressure. The results can provide references for optimizing the structural design and the selection of preloading pressure, which improves operation reliability. Full article

With the development of global hydropower, the scale of hydropower stations is increasing, and the operating conditions are becoming more complex, so the stable operation of hydropower stations is very important. The vibration of the turbine unit will cause resonance in the powerhouse, and the structural stability of the powerhouse will be affected. Many scholars pay attention to the stability of the turbine unit operation, and there are few studies on the powerhouse of the hydropower station. Therefore, this paper relies on the Weifang Hydropower Station project to study key issues such as the tensile strength of concrete and how to arrange steel bars to increase the structural stability by changing the material properties through FEA. Three schemes are designed to evaluate the safety of the powerhouse structure when the turbine unit is running through the safety factor. Our findings indicate that the stress variation patterns observed on the inner surface of the powerhouse remain consistent across different operating scenarios. Notably, along the spiral line of the worm section, we observed that the stress levels on the vertical loop line decrease gradually with increasing distance from the inlet. Conversely, stress concentrations arise near the inlet and the tongue. Additionally, it has been noted that the likelihood of concrete cracking increases significantly at the tongue region. Full article

In this paper, analyses of Francis turbine failures for powerful Pumped Hydraulic Energy Storage (PHES) are conducted. The structure is part of PHES Chaira, Bulgaria (HA4—Hydro-Aggregate 4). The aim of the study is to assess the structure-to-concrete embedding to determine the possible causes of damage and destruction of the HA4 Francis spiral casing units. The embedding methods that have been applied in practice for decades are discussed and compared to those used for HA4. A virtual prototype is built based on the finite-element method to clarify the influence of workloads under the generator mode. The stages of the simulation include structural analysis of the spiral casing and concrete under load in generator mode, as well as structural analysis of the spiral casing under loads in generator mode without concrete. Both simulations are of major importance. Since the failure of the surface between the turbine, the spiral casing, and the concrete is observed, the effect of the growing contact gap (no contact) is analyzed. The stresses, strains, and displacements of the turbine units are simulated, followed by an analysis for reliability. The conclusions reveal the possible reasons for cracks and destruction in the main elements of the structure. Full article

This work presents a new developed assessment methodology based on strength reduction and finite element methods which is suitable for existing large reinforced concrete structures commonly used in hydraulic constructions. The methodology is based on a reloading phase of the finite element model and is preceded by an intermediate reduction phase of concrete tensile strength and an initial loading phase up to service level. Rosenblueth’s point estimate method was used to compute a global resistance factor and to deduce a design resistance value of the structure. After validations, the methodology was applied to two existing complex and large hydraulic structures: a spiral case and a draft tube. If compared with existing methodologies using sophisticated non-linear finite element methods, the developed approach is simpler, more practical, and provides results that are on the conservative side. Considering the difficulties in characterizing the tensile peak and post-peak strength of concrete, along with uncertainties regarding the damage conditions of facilities, the developed methodology is deemed robust and well suited for assessing existing critical large reinforced concrete infrastructures. Full article

The spiral case structure is an essential part of a hydropower station. To accurately explore the joint load-bearing effect of the cushion-spiral case structure, a cushion-spiral case structure with a high HD value was selected, modeled, and analyzed in this study. The reliability of the model was verified through measured data. Given the contact relation between the spiral case and the cushion, the cushion laying range was used as the control parameter to investigate its impact on the joint bearing capacity of the structure. In addition, the concrete damage theory was introduced to probe the damage mechanism of the structure under assumed extreme working conditions. The steel spiral case bears most of the internal water pressure in the joint bearing system, and the bearing ratio of the surrounding concrete and reinforcement decreases with the increase in the cushion wrap angle. A 1.1–1.2 overload head is the main section that forms penetrating cracks. For the spiral case structure with a high HD value, a reasonable cushion can significantly reduce the damage level of the surrounding concrete and regulate the uneven lifting of the turbine pier and the shear strength of the stay ring. This study can provide reference points for the spiral case arrangement and range and the structural failure response under extreme working conditions. Full article

A spiral case structure (SCS) plays a significant role in the safe and reliable operation of a hydroelectric power plant (HPP). In an HPP with 700 MW class turbine in China, a structural deformation accident happened in the construction period causing severe loss. Based on in-situ measured data, this study focuses on two major differences of this SCS that might cause the accident: (a) the construction condition, and (b) the shape of steel spiral case (SSC). The accident is reproduced in numerical study, and the simulation results agree reasonably well with in-situ measured data. The results show that the construction condition is a main factor causing the accident, but it is not the only cause of the raising deformation. The findings reveal that the post-accident stresses of steel structures are still at a relatively low level, and it would not be a major concern. The study also shows that the SSC with non-circle sections tends to have larger deformation under internal water pressure, and the deformation of the stay ring needs more attention in the construction period. The major limitation of this study is that this study merely focuses on the construction period. If such SCSs were to be used in a wider range, a follow-up study focusing on the operation period should be considered. Full article

Temporary internal water pressure (IWP) during a construction period fundamentally affects the structural performance of spiral case structures (SCSs) in pumped-storage power plants (PSPPs). However, its actual role is rarely studied. This study focuses on this issue considering the complex construction-to-operation process of SCSs. An ABAQUS-based complete simulation procedure (CSP) is used with contact non-linearity considered. The contact-closing ratio is introduced to quantitively describe the contact status, and different design philosophies for temporary IWP are compared. The results show that the temporary IWP should be no greater than 80% of the minimum static headwater to ensure an overall contact-closing status under normal operating conditions in this study. The findings reveal that the cracking risk of concrete is negatively correlated with temporary IWP, while high temporary IWP is not suggested. Moreover, the stay ring actually shares a certain part of the unbalanced hydraulic thrust, which cannot be ignored. The limitation of this study might mainly lie in the idealized linear-elastic description of concrete. The temporary IWP should be designed with overall consideration of the IWP under normal operating conditions, the IWP-jointly-resisting status and design demands. Full article